Bicycle hub for disc brake

ABSTRACT

A bicycle brake disc hub is provided for use with tangential bicycle spokes. The bicycle hub basically has a hub axle and a hub body with a brake rotor attachment portion integral formed therewith as a one-piece, unitary member. The hub axle has a center axis extending between a first end and a second end. The hub body has an interior passageway with the hub axle being rotatably supported therein. The hub body also has a set of first spoke openings circumferentially arranged around the hub body. The brake rotor attachment portion is located at a first end section of the center tubular portion. The first spoke openings are located adjacent the brake rotor attachment portion. The first spoke openings extend through the first end section of the center tubular portion of the hub body. The brake rotor attachment portion having a plurality of through bores. The through bores receive a bolt therethrough with a nut coupled the end of the bolt

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to a bicycle disc brake hub. More specifically, the present invention relates a bicycle disc brake hub with an integral rotor mounting portion.

2. Background Information

Bicycling is becoming an increasingly popular form of recreation as well as a means of transportation. Moreover, bicycling has become a very popular competitive sport. Whether the bicycle is used for recreation, transportation or competition, the bicycle industry is constantly improving their components. Recently, the braking systems for bicycles have included the use of disc brakes. The use of disc brakes has resulted in modifications to the bicycle hub of the bicycle wheel so that a brake rotor can be mounted thereon.

The most basic bicycle wheels have a hub, a plurality of spokes and an annular rim. The hub is attached to a part of the frame of the bicycle for relative rotation. The inner ends of the spokes are coupled to the hub and extend outwardly from the hub. The annular rim is coupled to the outer ends of the spokes and has an outer portion for supporting a pneumatic tire thereon. Typically, the spokes of the bicycle wheel are thin metal wire spokes. The ends of the hub are provided with a flange that is used to couple the spokes to the hub. In particular, holes are provided in the hub flanges. The wire spokes are usually bent on their inner end and provided with an enlarged head or flange that is formed in the shape of a nail head. The inner end is supported in one of the holes in one of the hub flanges. The outer ends of the spokes typically are provided with threads for engaging spoke nipples, which secure the outer ends of the wire spokes to the rim. In particular, the spoke nipples have flanges, which engage the interior surface of the rim.

With a spoke constructed in this manner, the nipples are installed in nipple holes formed in the rim. The spokes are inserted sideways through the holes in the hub flange until the enlarged head or flanges of the spokes engaging the areas surrounding the holes in the hub flange. The male threads on the ends of the spokes are threaded into the female threads of the spoke nipples installed in the openings of the rim.

When the hub is a brake disc hub or is a rear hub, installation and/or replacement of the spokes can be difficult. In the case of a disk brake hub, one end of the hub usually has a rotor mounting portion. Often, the rotor mounting portion is a plurality of blind bores that receive bolts to directly mount the brake disc rotor to the end of the hub. Thus, the brake disc rotor makes it difficult to insert the spokes in a sideways direction. Likewise, if the hub is a rear hub, the sprockets can be obstacles to install or replace spokes.

Moreover, the blind bores of the hubs are time consuming to form and often become damaged. When the blind bores become damaged, the entire hub must be replaced. Thus, these prior hubs are expensive to manufacture and replace.

In view of the above, there exists a need for a bicycle hub which overcomes the above mentioned problems in the prior art. This invention addresses this need in the prior art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

SUMMARY OF THE INVENTION

One object of the present invention is to provide a bicycle hub that has an integrated brake rotor attachment portion.

Another object of the present invention is to provide a bicycle hub that is relatively lightweight.

The foregoing objects can be attained by providing a bicycle brake disc hub for use with bicycle spokes. The bicycle hub basically includes a hub axle and a hub body a brake rotor attachment portion. The hub axle has a center axis extending between a first end and a second end. The hub body has a center tubular portion defining an interior passageway with the hub axle being rotatably supported therein. The brake rotor attachment portion is located at a first end section of the center tubular portion. The first spoke openings are located adjacent the brake rotor attachment portion. The first spoke openings extend through the first end section of the center tubular portion of the hub body. The brake rotor attachment portion is integrally formed with the center tubular portion as a one-piece, unitary member. The brake rotor attachment portion having a plurality of through bores.

These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a side elevational view of a conventional bicycle with front and rear brake disc hubs in accordance with a first embodiment of the present invention;

FIG. 2 is a side elevational view of the rear wheel of the bicycle illustrated in FIG. 1 with the sprockets removed;

FIG. 3 is partially exploded perspective view of the rim, one of the spokes and one of the spoke nipples of the bicycle illustrated in FIG. 1;

FIG. 4 is a side elevational view of the rear brake disc hub of the rear wheel illustrated in FIG. 2 with the sprockets removed;

FIG. 5 is a side elevational view of the rear brake disc hub of the rear wheel illustrated in FIG. 3 with certain portions broken away for purposes of illustration;

FIG. 6 is a left end elevational view of the rear brake disc hub body illustrated in FIGS. 4 and 5 with the brake disc rotor bolts mounted thereto;

FIG. 7 is a left end elevational view of the rear brake disc hub body illustrated in FIGS. 4 and 5 with the brake disc rotor bolts removed;

FIG. 8 is a left end elevational view of the rear brake disc hub body illustrated in FIGS. 4 and 5 with unthreaded bolt holes;

FIG. 9 is a partial transverse cross-sectional view of the rear brake disc hub body illustrated in FIGS. 4 and 5 as seen along section line 9—9 of FIG. 4;

FIG. 10 is a partial transverse cross-sectional view of the rear brake disc hub body illustrated in FIGS. 4 and 5 as seen along section line 10—10 of FIG. 4;

FIG. 11 is a partial elevational view of one of the spoke openings of the rear brake disc hub body illustrated in FIGS. 4 and 5;

FIG. 12 is a schematic view of portion of the rear brake disc hub body illustrated in FIGS. 4 and 5 with two spokes extending outwardly therefrom;

FIG. 13 is a partial cross-sectional view of the first seal for the rear brake disc hub body illustrated in FIGS. 4 and 5;

FIG. 14 is a partial cross-sectional view of the second seal for the rear brake disc hub body illustrated in FIGS. 4 and 5;

FIG. 15 is a side elevational view of the front brake disc hub of the front wheel illustrated in FIG. 1;

FIG. 16A is a partial cross-sectional view of a modified front brake disc hub with threaded through bores or bolt holes formed in the brake rotor attachment portion;

FIG. 16 is a side elevational view of the front brake disc hub of the front wheel illustrated in FIG. 1 with certain portions broken away for purposes of illustration;

FIG. 17 is a partial cross-sectional view of the first seal for the front brake disc hub body illustrated in FIGS. 15 and 16;

FIG. 18 is a partial cross-sectional view of the second seal for the front brake disc hub body illustrated in FIGS. 15 and 16;

FIG. 19 is a perspective view of a first embodiment of a spoke opening cover for the hubs of the present invention;

FIG. 20 is a side elevational view of the front brake disc hub with the spoke opening cover illustrated in FIG. 19 installed thereon;

FIG. 21 is a perspective view of a second embodiment of a spoke opening cover for the hubs of the present invention;

FIG. 22 is a side elevational view of the front brake disc hub with the spoke opening cover illustrated in FIG. 21 installed thereon;

FIG. 23 is an inside elevational view of a third embodiment of a spoke opening cover for the hubs of the present invention;

FIG. 24 is an edge elevational view of the spoke opening cover illustrated in

FIG. 23 for the hubs of the present invention;

FIG. 25 is a side elevational view of the front brake disc hub with the spoke opening cover illustrated in FIGS. 23 and 24 installed thereon;

FIG. 26 is a side elevational view of the rear brake disc hub in accordance with a second embodiment of the present invention with the sprockets removed;

FIG. 27 a side elevational view of the rear brake disc hub illustrated in FIG. 26 in accordance with a second embodiment of the present invention with certain portions broken away for purposes of illustration;

FIG. 28 is a side elevational view of the front brake disc hub in accordance with a second embodiment of the present invention with the sprockets removed; and

FIG. 29 a side elevational view of the front brake disc hub illustrated in FIG. 28 in accordance with a second embodiment of the present invention with certain portions broken away for purposes of illustration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIGS. 1-3, a bicycle 10 is illustrated with certain parts being modified in accordance with the present invention as discussed below. The bicycle 10 basically has a frame 12 with a front fork 13 movably coupled thereto. A rear wheel 14 is rotatably coupled to a rear portion of the frame 12, while a front wheel 16 is rotatably coupled to the front fork 13. The frame 12 also has a seat 18 adjustably coupled to frame 12, a handlebar 19 coupled to front fork 13 for turning front wheel 16 and a drive train 20 for propelling bicycle 10. The bicycle 10 is also provided with a pair of disc brake assemblies 21 having a caliper 21 a and a brake lever 21 b.

Since these parts of bicycle 10 are well known in the art, these parts will not be discussed or illustrated in detail herein, except as they are modified in accordance with the present invention. Moreover, various conventional bicycle parts such as brakes, derailleurs, additional sprocket, etc., which are not illustrated and/or discussed in detail herein, can be used in conjunction with the present invention.

As seen in FIG. 2, the rear wheel 14 has a rear hub 22, a plurality of spokes 24 extending outwardly from the rear hub 22, a rim 26 coupled to the outer ends of spokes 24 by spoke nipples 28, and a tire 30 located on the outer surface of rim 26. The rear hub 22 is also provided with a brake disc rotor 32 that is attached to the rear hub 22 by six blots 32 a and six nuts 32 b, as explained below. While the illustrated embodiment is a thirty-six spoke wheel, it will be apparent to those skilled in the art from this disclosure that other spoke arrangements are possible without departing from the present invention. For example, a thirty-two spoke wheel or a forty spoke wheel can be constructed in accordance with the present invention without departing from the present invention. Basically, the number of spoke openings depends upon the rim to be used with the hub of the present invention.

Preferably, the spokes 24, the rim 26 and spoke nipples 28 are all conventional parts that are used with the rear hub 22 of the present invention as seen in FIG. 3. In other words, the unique design of the rear hub 22 allows it to be used with conventional parts, e.g., tangential spokes 24 and a conventional rim 26. Accordingly, when the rear wheel 14 is assembled, the spokes 24 extend tangentially from an imaginary circle centered on the center axis of rotation of rear hub 22. In the illustrated embodiment of FIGS. 2-5, the rear hub 22 and the rim 26 has thirty-six of the spokes 24 coupled therebetween.

The term “tangential spokes” are spokes that have a straight section 24 a and a bent end 24 b with an enlarged head 24 c such that straight section 24 a extends at an angle of about 950 relative to the bent end 24 b. Such spokes are well known in the bicycle art. As seen in FIG. 3, the spokes 24 of the illustrated embodiment each have an outer threaded end 24 d that is located at the opposite end of the center straight section 24 a from the bent end 24 b (inner end portion) with the enlarged head 24 c. The bent end 24 b has a center axis that forms an angle of about 95° with the center axis of the straight section 24 a. The bent ends 24 b of the spokes 24 are designed to be received within the first and second spoke openings. In particular, the enlarged heads 24 c of the spokes 24 engage an interior surface of the hub body 38 with the straight sections 24 a extending substantially tangentially to an imaginary circle with a center on the center axis of rotation of the rear hub 22.

The rim 26 can be any conventional rim that has a plurality of spoke holes 34 for receiving the spoke nipples 28 for attaching the outer threaded ends 24 d of the spokes 24 thereto. In the illustrated embodiment, the rim 26 is a conventional steel or alloy rim having a U-shaped cross section with thirty-six spoke holes 34. The spoke holes 34 are equally spaced apart in a circumferential direction. The spoke holes 34 are preferably lie in a single plane P that divides the cross section in half as seen in FIG. 3. Of course, rims with fewer or more spoke holes 34 can be used with a hub of the present invention, if needed and/or desired. For example, the rim 26 can have thirty-two spoke holes instead of thirty-six spoke holes, if the rear hub 22 is modified to have fewer holes as explained below.

Rear Hub 22

As best seen in FIG. 5, the rear hub 22 basically includes a hub axle 36, a hub body or shell 38, a first bearing assembly 40 a, a second bearing assembly 40 b, a first spoke seal 42 a, a second spoke seal 42 b, a freewheel 44 and a quick release mechanism 46. Of the parts of rear hub 22, only the hub body 38 and the first and second spoke seals 42 a and 42 b are non-conventional parts. The remaining parts of rear hub 22 are relatively conventional, and thus, the remaining parts of rear hub 22 will not be discussed or illustrated in detail herein.

The hub axle 36 has a center axis A extending between a first end 36 a and a second end 36 b. The quick release mechanism 46 extends through a center bore 36 c of the hub axle 36 such that the quick release mechanism 46 is coupled to the hub axle 36 in a conventional manner. The first and second ends 36 a and 36 b of the hub axle 36 are threaded for receiving a pair of nuts 50 a and 50 b that applies an axial force on the hub body 38, the bearing assemblies 40 a and 40 b, the spoke seals 42 a and 42 b, and the freewheel 44. First and second bearing assemblies 40 a and 40 b rotatably mount the hub body 38 with the freewheel 44 on the hub axle 36. The freewheel 44 allows the hub axle 36 to rotate freely relative to the hub body 38 in one direction, but fixedly couples the hub axle 36 relative to the hub body 38 in the opposite rotational direction.

The hub body 38 is illustrated in accordance with one embodiment of the present invention. In this embodiment, the hub body 38 is a hollow member that defines an interior passageway 52 with the hub axle 36 being rotatably supported therein by the first and second bearing assemblies 40 a and 40 b. Thus, the hub body 38 is a substantially tubular member. Specifically, the hub body 38 has a center tubular portion 38 c with first and second end sections 38 a and 38 b being integral formed with the center tubular portion 38 c as a one-piece, unitary member. The first end section 38 a has an integrally mounted brake rotor attachment portion 38 d, while a second end section 38 b has the freewheel 44 fixedly coupled thereto.

A set of first spoke openings 60 a are provided at the first end section 38 a of the hub body 38 for receiving the bent ends 24 b of the spokes 24. Similarly, the second end section 38 b of the hub body 38 is provided with a second set of spoke openings 60 b for receiving the bent ends 24 b of the spokes 24. In the illustrated embodiment, the first end section 38 a is provided with nine of the first spoke openings 60 a and the second end section 38 b is provided with nine of the second spoke openings 60 b. The spoke openings 60 a and 60 b are equally spaced apart about the circumference of the hub body 38. Each of the spoke openings 60 a and 60 b are also designed to receive two spokes 24 as explained below. Accordingly, the rear hub 22 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

Preferably, the first and second sets of spoke openings 60 a and 60 b are identical. The first and second spoke openings 60 a and 60 b are designed to be used with conventional tangential spokes 24. Of course, it is possible that the first and second sets of spoke openings 60 a and 60 b can be different such that tangential spokes 24 are used in one end of the hub body 38 and a different types of spokes are used in the other end of the hub body 38. The first spoke openings 60 a are circumferentially arranged around the hub body 38 adjacent to the brake rotor attachment portion 38d. Preferably, the first spoke openings 60 a are spaced axially inward of the brake rotor attachment portion 38 d so that brake disc rotor 32 can be easily attached with the bolts 32 a and nuts 32 b.

In this embodiment, the first and second spoke openings 60 a and 60 b are elongated slots that are each provided with an insertion portion 61 and a pair of retaining portions 62. Accordingly, each of the spoke openings 60 a and 60 b is designed to have a pair of spokes 24 retained therein with the spokes 24 extending in opposite directions.

The insertion portion 61 of each spoke opening is located between the pair of retaining portions 62 of each spoke opening. Each insertion portion 61 is formed by a pair of opposed curved surfaces 64 that are spaced apart so as to be equal to or slightly larger than the widths or diameters of the enlarged heads 24 c of the spokes 24. Thus, the inner ends (bent ends 24 b with enlarged heads 24 c) of the spokes 24 can be easily inserted into the spoke openings 60 a and 60 b through the insertion portions 61.

The retaining portions 62 have smaller widths or diameters than the insertion portions 61. More specifically, the diameters or widths of the retaining portions 62 are smaller than the diameters or widths of the enlarged heads 24 c of the spokes 24 so as to retain the spokes 24 within the spoke openings 60 a and 60 b. The retaining portions 62 are each preferably defined by a partial cylindrical surface 66 that is connected to the curved surfaces 64 of the associated insertion portion 61 by a pair of straight surfaces 68.

The spoke openings 60 a and 60 b are formed as elongated slots that are angled relative to the axis A. Accordingly, the insertion portions 61 are arranged in a circumferential pattern with one set of the retaining portions 62 being located axially outward from the insertion portions 61 and the other set of retaining portions 62 being spaced axially inward from the insertion portions 61. In other words, a first set of retaining portions 62 form an outer circumferential row of the retaining portions 62, and a second set of the retaining portions 62 form an inner circumferential row of retaining portions 62 with the insertion portions 61 being located between the rows of retaining portions 62.

Preferably, the insertion portion 61 and the retaining portions 62 of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 62 of the spoke openings 60 a and 60 b are tapered to avoid sharp edges engaging the spokes 24.

Each of the insertion portions 61 has a center longitudinal axis C₁ that passes through the center axis A of the hub axle 36. The retaining portions 62, on the other hand, have center longitudinal axes C₂ that are parallel to the center longitudinal axis C₁ of the insertion portion 61 for each of the spoke openings 60 a and 60 b. Thus, the center longitudinal axes C₂ of the retaining portions 62 do not pass through the center axis of the hub axle 36. Rather, the center longitudinal axes C₂ of the retaining portions 62 are angled with respect to center axis A. Preferably, the center longitudinal axis C₂ of each retaining portion 62 is angled between about 5° and about 20° from a radial orientation in the hub body 38. In the illustrated embodiment, the retaining portions 62 are angled about 10° with respect to center axis A for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 62 are preferably angled about 11° with respect to center axis A. This angled configuration of the retaining portions 62 results in the straight sections 24 a of the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 38. Moreover, this angled configuration of the retaining portions 62 allows the straight sections 24 a of the spokes 24 to be easily aligned with the spoke holes 34 of the rim 26 without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees. Of course, the less bending of the spokes 24, the better.

If the retaining portions 62 were formed with their center axis passing through the center axis A of the hub axle 36, then the conventional spokes 24 would be placed under excessive bending forces, which could result in the spokes 24 breaking during use of the wheel. In particular, if the retaining portions 62 have their center axes passing through the center of the hub axle 36, then the center straight section 24 a would have to be bent from 95° to 108° for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. In contrast, with the retaining portions 62 of the spokes 24 being angled, the amount of bending of the spokes 24 can be reduced and/or eliminated.

The brake rotor attachment portion 38 d is integrally formed with the center tubular portion 38 c of the hub body 38 as a one-piece, unitary member. In the illustrated embodiment, the brake rotor attachment portion 38 d is formed with six attachment members or points with through bores 70. While six individual attachment points are illustrated, it will be apparent to those skilled in the art from this disclosure that fewer or more attachment points can be utilized. Moreover, it will be apparent to those skilled in the art from this disclosure that the attachment portions could be a continuous flange, if needed and/or desired. The through bore 70 can be threaded (FIG. 7) or unthreaded (bores 70′ of FIG. 8). By using through bores 70 instead of blind bores, the rear hub 22 can be easily manufactured at a relatively lower cost.

As seen in FIG. 8, the through bores 70″ can be unthreaded bores. In the case of unthreaded through bores 70″, the bolts 32 a extend into openings in the brake disc rotor 32 and then through the through bores 70″. The free ends of the bolts 32 a have nuts 32 b threaded thereon for attaching the brake disc rotor 32 to the hub body 38. This arrangement allows the hub body 38 and the brake rotor attachment portion 38 d to be formed out of the same a lightweight material, such as aluminum. In this arrangement, the hub body 38 does not need to be replaced if the through bores 70″become damaged.

As seen in FIG. 7, the through bores 70 are threaded. In the case of threaded through bores 70, the bolts 32 a extend into openings in the brake disc rotor 32 and then threaded into the through bores 70. Optionally, the free ends of the bolts 32 a can have the nuts 32 b threaded thereon for more securely attaching the brake disc rotor 32 to the hub body 38. In this arrangement, if the threads of through bores 70 become damaged, the hub body 38 does not need to be replaced. Rather, the bolts 32 a and the nuts 32 b securely attach the brake disc rotor 32 to the hub body 38.

Bearing assemblies 40 a and 40 b rotatably supports hub body 38 on hub axle 36. The bearing assembly 40 a basically includes a plurality of balls 74 a located between an inner race member 76 a and an outer race member 78 a. Similarly, the bearing assembly 40 b basically includes a plurality of balls 74 b located between an inner race member 76 b and an outer race member 78 b. Since bearing assemblies 40 a and 40 b are well known in the bicycle art, they will not be discussed or illustrated in detail herein.

Turning now to FIGS. 13 and 14, the spoke seals 42 a and 42 b are arranged in the interior passageway 52 of the hub body 38 so as to be adjacent the spoke openings 60 a and 60 b to isolate the spoke openings 60 a and 60 b from the hub axle 36. In other words, the spoke seals 42 a and 42 b prevent contaminants from entering the rear hub 22 through the spoke openings 60 a and 60 b. The spoke seals 42 a and 42 b are preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement. Moreover, it will be apparent to those skilled in the art from this disclosure that while the spoke seals 42 a and 42 b are illustrated as a pair of separate sealing members, the spoke seals 42 a and 42 b can be formed as a one-piece, unitary member.

In the preferred embodiment, the spoke seals 42 a and 42 b also aid in the assembly of the spokes 24 with the hub body 38 and the rim 26. Specifically, in the preferred embodiments, the seals 42 a and 42 b are arranged so that they restrain movement of the spokes 24 within the spoke openings 60 a and 60 b so that the bent ends 24 b of the spokes 24 stays in the retaining portions 62 of the spoke openings 60 a and 60 b.

In the illustrated embodiment, the spoke seal 42 a has a tubular section 80 a and a center annular flange 82 a. The center annular flange 82 a extends in a circumferential direction about the tubular section 80 a. The center annular flange 82 a can either contact the interior surface of the tubular section 80 a or be spaced from the tubular section 80 a. The ends 84 a and 86 a of the tubular section 80 a are configured to engage a ring member 88 a and an abutment 90 a of the inner surface of the hub body 38. Of course, the particular shape of the ends 84 a and 86 a will vary depending on the shape of the hub body 38 and its internal components. Preferably, ends 84 a and 86 a of the tubular section 80 a are annular flanges that contact the interior surface of the tubular section 80 a to form an isolated area beneath the spoke openings 60 a. This isolated area beneath the spoke openings 60 a is a continuous annular space.

When the rear hub 22 is assembled, an axial force is applied to the ends 84a and 86 a of the tubular section 80 a to form annular seals therebetween. Accordingly, the spoke seal 42 a isolates a first interior section of the interior passageway 52 from the reminder of the interior passageway 52. This interior section formed by the spoke seal 42 a is continuous annular first space located beneath the spoke openings 60 a.

The center annular flange 82 a is preferably aligned with a circumferentially passing through the centers axes C₁ of the insertion portions 61 of the first spoke openings 60 a. Thus, the center annular flange 82 a is positioned to axially separate the two retaining portions 62 of each of the first spoke openings 60 a from each other. The center annular flange 82 a is also positioned to keep spokes 24 in the retaining portions 62 of the first spoke openings 60 a. Accordingly, when the enlarged heads 24 c of the spokes 24 are inserted into the insertion portions 61 of the spoke openings 60 a, the enlarged heads 24 c of the spokes 24 contact the center annular flange 82 a. The enlarged heads 24 c then pushes or deforms the center annular flange 82 a one way or the other so that the enlarged heads 24 c extends into the insertion portions 61 of the spoke openings 60 a. The spokes 24 are then moved or slid into one of the two retaining portions 62 of each of the spoke openings 60 a. The center annular flange 82 a will prevent the spokes 24 from accidentally falling out of the insertion portions 61 of the spoke openings 60 a. Thus, the center annular flange 82 a aids in the assembly of the rear wheel 14. In other words, the center annular flange 82 a must be moved or deformed again before the spokes 24 can be removed from the spoke openings 60 a. For added resiliency, an annular groove 92 a can be formed in the outer peripheral surface of the center flange 82 a.

Similar to the spoke seal 42 a, the spoke seal 42 b has a tubular section 80 b and a center annular flange 82 b. The center annular flange 82 a extends in a circumferential direction about the tubular section 80 a. Alternatively, the center annular flanges 82 a and 82 b of the spoke seals 42 a and 42 b can each have a pair of center annular flanges. The ends 84 b and 86 b of the tubular section 80 b are configured to engage a ring member 88 b and an abutment 90 b of the inner surface of the hub body 38. Of course, the particular shape of the ends 84 b and 86 b will vary depending on the shape of the hub body 38 and its internal components. Preferably, ends 84 b and 86 b of the tubular section 80 b are annular flanges that contact the interior surface of the tubular section 80 b to form an isolated area beneath the spoke openings 60 b. This isolated area beneath the spoke openings 60 b is a continuous annular space.

When the rear hub 22 is assembled, an axial force is applied to the ends 84 b and 86 b of the tubular section 80 b to form annular seals therebetween. Accordingly, the spoke seal 42 b isolates a second interior section of the interior passageway 52 from the reminder of the interior passageway 52. This interior section formed by the spoke seal 42 b is continuous annular second space located beneath the spoke openings 60 b.

Similar to the center annular flange 82 a, the center annular flange 82 b is preferably aligned with a circumferentially passing through the centers axes C₁ of the insertion portions 61 of the second spoke openings 60 b. Thus, the center annular flange 82 b is positioned to axially separate the two retaining portions 62 of each of the second spoke openings 60 b from each other. The center annular flange 82 b is also positioned to keep spokes 24 in the retaining portions 62 of the second spoke openings 60 b. Accordingly, when the enlarged heads 24 c of the spokes 24 are inserted into the insertion portions 61 of the spoke openings 60 b, the enlarged heads 24 c of the spokes 24 contact the center annular flange 82 b. The enlarged heads 24 c then pushes or deforms the center annular flange 82 b one way or the other so that the enlarged heads 24 c extends into the insertion portions 61 of the spoke openings 60 b. The spokes 24 are then moved or slid into one of the two retaining portions 62 of each of the spoke openings 60 b. The center annular flange 82 b will prevent the spokes 24 from accidentally falling out of the insertion portions 61 of the spoke openings 60 b. Thus, the center annular flange 82 b aids in the assembly of the rear wheel 14. In other words, the center annular flange 82 b must be moved or deformed again before the spokes 24 can be removed from the spoke openings 60 b. For added resiliency, an annular groove 92 b can be formed in the outer peripheral surface of the center flange 82 b.

The freewheels, such as the freewheel 44, are well known in the bicycle art, and thus, the freewheel 44 will not be illustrated or discussed in detail herein. The freewheel 44 is used to transmit a driving force from the chain to the rear bicycle wheel in one rotation direction only. The freewheel 44 allows the bicycle 10 to advance freely without any rotation of the pedals. The freewheel 44 is fastened to the rear hub 22 as integral part of the rear hub 22 in a conventional manner. The freewheel 44 has an outer tubular part 94, an inner tubular part 96 and a one-way clutch 98. The inner tubular part 96 is installed radially inwardly of the outer tubular part 94 so that the inner tubular part 96 is free to rotate relative to the outer tubular part 94. The one-way clutch 98 is installed between the outer tubular part 94 and inner tubular part 96 for transmitting the driving force from the outer tubular part 94 to the inner tubular part 96 in one rotational direction only. The outer tubular part 94 has a plurality of gears or sprockets (not shown) mounted thereon, while the inner tubular part 96 is usually mounted on the hub axle 36.

Front Hub 22′

Turning now to FIGS. 15 and 16, the front hub 22′ is illustrated in accordance with the present invention. The front hub 22′ is substantially the same as the rear hub 22, except that the front hub 22′ does not have a freewheel and the spoke openings 60 a′ and 60 b′ are angled in the opposite direction from spoke openings 60 a and 60 b of the rear hub 22. Moreover, the front hub 22′ is used with spokes 24 and rim 26 discussed above. Since the front hub 22′ is substantially the same as the rear hub 22, the front hub 22′ will not be discussed or illustrated in detail herein.

The front hub 22′ basically includes a hub axle 36′, a hub body or shell 38′, a first bearing assembly 40 a′, a second bearing assembly 40 b′, a first spoke seal 42 a′, a second spoke seal 42 b′ and a quick release mechanism 46′. Of the parts of front hub 22′, only the hub body 38′ and the first and second spoke seals 42 a′ and 42 b′ are nonconventional parts. The remaining parts of front hub 22′ are relatively conventional, and thus, the remaining parts of front hub 22′ will not be discussed or illustrated in detail herein.

The hub axle 36′ has a center axis A extending between a first end 36 a′ and a second end 36 b′. The quick release mechanism 46′ extends through a center bore 36 c′ of the hub axle 36′ such that the quick release mechanism 46′ is coupled to the hub axle 36′ in a conventional manner. The first and second ends 36 a′ and 36 b′ of the hub axle 36′ are threaded for receiving a pair of nuts 50 a′ and 50 b′ that applies an axial force on the hub body 38′, the bearing assemblies 40 a′ and 40 b′ and the spoke seals 42 a′ and 42 b′. First and second bearing assemblies 40 a′ and 40 b′ rotatably mount the hub body 38′ on the hub axle 36′.

The hub body 38′ is illustrated in accordance with one embodiment of the present invention. In this embodiment, the hub body 38′ is a hollow member that defines an interior passageway 52′ with the hub axle 36′ being rotatably supported therein by the first and second bearing assemblies 40 a′ and 40 b′. Thus, the hub body 38′ is a substantially tubular member. Specifically, the hub body 38′ has a center tubular portion 38 c′ with first and second end sections 38 a′ and 38 b′ being integral formed with the center tubular portion 38 c′ as a one-piece, unitary member. The first end section 38 a′ has an integrally mounted brake rotor attachment portion 38 d′.

A set of first spoke openings 60 a′ are provided at the first end section 38 a′ of the hub body 38′ for receiving the bent ends 24 b of the spokes 24. Similarly, the second end section 38 b′ of the hub body 38′ is provided with a second set of spoke openings 60 b′ for receiving the bent ends 24 b of the spokes 24. In the illustrated embodiment, the first end section 38 a′ is provided with nine of the first spoke openings 60 a′ and the second end section 38 b′ is provided with nine of the second spoke openings 60 b′. The spoke openings 60 a′ and 60 b′ are equally spaced apart about the circumference of the hub body 38′. Each of the spoke openings 60 a′ and 60 b′ are also designed to receive two spokes 24 as explained below. Accordingly, the front hub 22′ is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

Preferably, the first and second sets of spoke openings 60 a′ and 60 b′ are identical. The first and second spoke openings 60 a′ and 60 b′ are designed to be used with conventional tangential spokes 24. Of course, it is possible that the first and second sets of spoke openings 60 a′ and 60 b′ can be different such that tangential spokes 24 are used in one end of the hub body 38′ and a different types of spokes are used in the other end of the hub body 38′. The first spoke openings 60 a′ are circumferentially arranged around the hub body 38′ adjacent to the brake rotor attachment portion 38 d′. Preferably, the first spoke openings 60 a′ are spaced axially inward of the brake rotor attachment portion 38 d′ so that brake disc rotor 32′ can be easily attached with the bolts 32 a′ and nuts 32 b′.

In this embodiment, the first and second spoke openings 60 a′ and 60 b′ are elongated slots that are each provided with an insertion portion 61′ and a pair of retaining portions 62′. Accordingly, each of the spoke openings 60 a′ and 60 b′ is designed to have a pair of spokes 24 retained therein with the spokes 24 extending in opposite directions.

The insertion portion 61′ of each spoke opening is located between the pair of retaining portions 62′ of each spoke opening. Each insertion portion 61′ is formed by a pair of opposed curved surfaces 64′ that are spaced apart so as to be equal to or slightly larger than the widths or diameters of the enlarged heads 24 c of the spokes 24. Thus, the inner ends (bent ends 24 b with enlarged heads 24 c) of the spokes 24 can be easily inserted into the spoke openings 60 a′ and 60 b′ through the insertion portions 61′.

The retaining portions 62′ have smaller widths or diameters than the insertion portions 61′. More specifically, the diameters or widths of the retaining portions 62′ are smaller than the diameters or widths of the enlarged heads 24 c of the spokes 24 so as to retain the spokes 24 within the spoke openings 60 a′ and 60 b′. The retaining portions 62′ are each preferably defined by a partial cylindrical surface 66′ that is connected to the curved surfaces 64′ of the associated insertion portion 61′ by a pair of straight surfaces 68′.

The spoke openings 60 a′ and 60 b ‘are formed elongated slots that are angled relative to the axis A’. Accordingly, the insertion portions 61′ are arranged in a circumferential pattern with one set of the retaining portions 62′ being located axially outward from the insertion portions 61′ and the other set of retaining portions 62′ being spaced axially inward from the insertion portions 61′. In other words, a first set of retaining portions 62′ form an outer circumferential row of the retaining portions 62′, and a second set of the retaining portions 62′ form an inner circumferential row of retaining portions 62′ with the insertion portions 61′ being located between the rows of retaining portions 62′.

Preferably, the insertion portion 61′ and the retaining portions 62′ of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 62′ of the spoke openings 60 a′ and 60 b′ are tapered to avoid sharp edges engaging the spokes 24.

Each of the insertion portions 61′ has a center longitudinal axis C₁′ that passes through the center axis A′ of the hub axle 36′. The retaining portions 62′, on the other hand, have center longitudinal axes C₂′ that are parallel to the center longitudinal axis C₁′ of the insertion portion 61′ for each of the spoke openings 60 a′ and 60 b′. Thus, the center longitudinal axes C₂′ of the retaining portions 62′ do not pass through the center axis of the hub axle 36′. Rather, the center longitudinal axes C₂′ of the retaining portions 62′ are angled with respect to center axis A′. Preferably, the center longitudinal axis C₂′ of each retaining portion 62′ is angled between about 5° and about 20° from a radial orientation in the hub body 38′. In the illustrated embodiment, the retaining portions 62′ are angled about 10° with respect to center axis A for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 62′ are preferably angled about 11° with respect to center axis A′. This angled configuration of the retaining portions 62′ results in the straight sections 24 a of the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 38′. Moreover, this angled configuration of the retaining portions 62′ allows the straight sections 24 a of the spokes 24 to be easily aligned with the spoke holes 34 of the rim 26 without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees.

If the retaining portions 62′ were formed with their center axis passing through the center axis A of the hub axle 36′, then the conventional spokes 24 would be placed under excessive bending forces, which could result in the spokes 24 breaking during use of the wheel. In particular, if the retaining portions 62′ have their center axes passing through the center of the hub axle 36′, then the center straight section 24 a would have to be bent from 95° to 108° for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. In contrast, with the retaining portions 62′ of the spokes 24 being angled, the amount of bending of the spokes 24 can be reduced and/or eliminated.

The brake rotor attachment portion 38 d′ is integrally formed with the center tubular portion 38 c′ of the hub body 38′ as a one-piece, unitary member. In the illustrated embodiment, the brake rotor attachment portion 38 d′ is formed with six attachment members or points with through bores 70′. While six individual attachment points are illustrated, it will be apparent to those skilled in the art from this disclosure that fewer or more attachment points can be utilized. Moreover, it will be apparent to those skilled in the art from this disclosure that the attachment portions could be a continuous flange, if needed and/or desired. The through bore 70′ can be unthreaded as seen in FIG. 16. By using through bores 70′ instead of blind bores, the front hub 22′ can be easily manufactured at a relatively lower cost.

In the case of unthreaded through bores 70′ as seen in FIG. 16, the bolts 32 a′ extend into openings in the brake disc rotor 32′ and then through the through bores 70′. The free ends of the bolts 32 a′ have nuts 32 b′ threaded thereon for attaching the brake disc rotor 32′ to the hub body 38′. This arrangement allows the hub body 38′ and the brake rotor attachment portion 38 d′ to be formed out of the same a lightweight material, such as aluminum. Moreover, the hub body 38′ does not need to be replaced if the through bores 70′ become damaged.

As seen in FIG. 16A, a modified front brake disc hub 38″ is illustrated having a brake rotor 38 d″ with threaded through bores or bolt holes 70″. In the case of threaded through bores 70″, the bolts 32 a′ extend into openings in the brake disc rotor 32′ and then threaded into the through bores 70″ of the hub body 38″. Optionally, the free ends of the bolts 32 a′ can have the nuts 32 b′ threaded thereon for more securely attaching the brake disc rotor 32′ to the hub body 38″. In this arrangement, if the threads of through bores 70″ become damaged, the hub body 38″ does not need to be replaced. Rather, the bolts 32 a′ and the nuts 32 b′ securely attach the brake disc rotor 32′ to the hub body 38″.

Bearing assemblies 40 a′ and 40 b′ rotatably supports hub body 38′ on hub axle 36′. The bearing assembly 40 a′ basically includes a plurality of balls 74 a′ located between an inner race member 76 a′ and an outer race member 78 a′. Similarly, the bearing assembly 40 b′ basically includes a plurality of balls 74 b′ located between an inner race member 76 b′ and an outer race member 78 b′. Since bearing assemblies 40 a′ and 40 b′ are well know in the bicycle art, they will not be discussed or illustrated in detail herein.

Turning now to FIGS. 17 and 18,the spoke seals 42 a′ and 42 b′ are arranged in the interior passageway 52′ of the hub body 38′ so as to be adjacent the spoke openings 60 a′ and 60 b′ to isolate the spoke openings 60 a′ and 60 b′ from the hub axle 36. In other words, the spoke seals 42 a′ and 42 b′ prevent contaminants from entering the front hub 22′ through the spoke openings 60 a′ and 60 b′. The spoke seals 42 a′ and 42 b′ are preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement. Moreover, it will be apparent to those skilled in the art from this disclosure that while the spoke seals 42 a′ and 42 b′ are illustrated as a pair of separate sealing members, the spoke seals 42 a′ and 42 b′ can be formed as a one-piece, unitary member.

In the preferred embodiment, the spoke seals 42 a′ and 42 b′ also aid in the assembly of the spokes 24 with the hub body 38′ and the rim 26. Specifically, in the preferred embodiments, the seals 42 a′ and 42 b′ are arranged so that they restrain movement of the spokes 24 within the spoke openings 60 a′ and 60 b′ so that the bent ends 24 b of the spokes 24 stays in the retaining portions 62′ of the spoke openings 60 a′ and 60 b′.

In the illustrated embodiment, the spoke seal 42 a′ has a tubular section 80 a′ and a center annular flange 82 a′. The center annular flange 82 a′ extends in a circumferential direction about the tubular section 80 a′. The ends 84 a′ and 86 a′ of the tubular section 80 a′ are configured to engage a ring member 88 a′ and an abutment 90 a′ of the inner surface of the hub body 38′. Of course, the particular shape of the ends 84 a′ and 86 a′ will vary depending on the shape of the hub body 38′ and its internal components. In other words, the spoke seal 42 a′ functions the same way as the spoke seal 42 a of the rear hub 22, but has a slightly modified ends 84 a′ and 86 a′ to accommodate front hub 22′.

When the front hub 22′ is assembled, an axial force is applied to the ends 84 a′ and 86 a′ of the tubular section 80 a′ to form annular seals therebetween. Accordingly, the spoke seal 42 a′ isolates a first interior section of the interior passageway 52′ from the reminder of the interior passageway 52′. This interior section formed by the spoke seal 42 a′ is continuous annular first space located beneath the spoke openings 60 a′.

The center annular flange 82 a′ is preferably aligned with a circumferentially passing through the centers axes C₁′ of the insertion portions 61′ of the first spoke openings 60 a′. Thus, the center annular flange 82 a′ is positioned to axially separate the two retaining portions 62′ of each of the first spoke openings 60 a′ from each other. The center annular flange 82 a′ is also positioned to keep spokes 24 in the retaining portions 62′ of the first spoke openings 60 a′. Accordingly, when the enlarged heads 24 c of the spokes 24 are inserted into the insertion portions 61 of the spoke openings 60 a′, the enlarged heads 24 c of the spokes 24 contact the center annular flange 82 a′. The enlarged heads 24 c then pushes or deforms the center annular flange 82 a′ one way or the other so that the enlarged heads 24 c extends into the insertion portions 61′ of the spoke openings 60 a′. The spokes 24 are then moved or slid into one of the two retaining portions 62′ of each of the spoke openings 60 a. The center annular flange 82 a′ will prevent the spokes 24 from accidentally falling out of the insertion portions 61′ of the spoke openings 60 a′. Thus, the center annular flange 82 a′ aids in the assembly of the front wheel 16. In other words, the center annular flange 82 a′ must be moved or deformed again before the spokes 24 can be removed from the spoke openings 60 a′. For added resiliency, an annular groove 92 a′ can be formed in the outer peripheral surface of the center flange 82 a′.

Similar to the spoke seal 42 a′, the spoke seal 42 b′ has a tubular section 80 b′ and a center annular flange 82 b′. The center annular flange 82 a′ extends in a circumferential direction about the tubular section 80 a′. Alternatively, the center annular flanges 82 a′ and 82 b′ of the spoke seals 42 a′ and 42 b′ can each have a pair of center annular flanges. The ends 84 b′ and 86 b′ of the tubular section 80 b′ are configured to engage a ring member 88 b′ and an abutment 90 b′ of the inner surface of the hub body 38′. Of course, the particular shape of the ends 84 b′ and 86 b′ will vary depending on the shape of the hub body 38′ and its internal components. When the front hub 22′ is assembled, an axial force is applied to the ends 84 b′ and 86 b′ of the tubular section 80 b′ to form annular seals therebetween. Accordingly, the spoke seal 42 b′ isolates a second interior section of the interior passageway 52′ from the reminder of the interior passageway 52′. This interior section formed by the spoke seal 42 b′ is continuous annular second space located beneath the spoke openings 60 b′.

Similar to the center annular flange 82 a′, the center annular flange 82 b′ is preferably aligned with a circumferentially passing through the centers axes C₁ of the insertion portions 61′ of the second spoke openings 60 b′. Thus, the center annular flange 82 b′ is positioned to axially separate the two retaining portions 62′ of each of the second spoke openings 60 b′ from each other. The center annular flange 82 b′ is also positioned to keep spokes 24 in the retaining portions 62′ of the second spoke openings 60 b′. Accordingly, when the enlarged heads 24 c of the spokes 24 are inserted into the insertion portions 61′ of the spoke openings 60 b′, the enlarged heads 24 c of the spokes 24 contact the center annular flange 82 b′. The enlarged heads 24 c then pushes or deforms the center annular flange 82 b′ one way or the other so that the enlarged heads 24 c extends into the insertion portions 61′ of the spoke openings 60 b′. The spokes 24 are then moved or slid into one of the two retaining portions 62 of each of the spoke openings 60 b′. The center annular flange 82 b′ will prevent the spokes 24 from accidentally falling out of the insertion portions 61′ of the spoke openings 60 b′. Thus, the center annular flange 82 b′ aids in the assembly of the front wheel 16. In other words, the center annular flange 82 b′ must be moved or deformed again before the spokes 24 can be removed from the spoke openings 60 b′. For added resiliency, an annular groove 92 b′ can be formed in the outer peripheral surface of the center flange 82 b′.

Spoke Opening Covers

As seen in FIGS. 19 and 20, a spoke opening cover 100 in accordance with one embodiment of the present invention is illustrated for use with the front hub 22′ of FIGS. 15 and 16. Of course, the spoke opening cover 100 can be used with the rear hub 22 of FIGS. 4 and 5 by turning the spoke opening cover 100 inside out to reverse the direction of the slits 102. Although for purposes of brevity, the spoke opening cover 100 will only be illustrated with the front hub 22′.

The spoke opening cover 100 is used to limit or prevent contaminants from entering the hub body 38 or 38′ via the spoke openings 60 a, 60 a′ or 60 b, 60 b′, respectively. The spoke opening cover 100 can be used instead of the spoke seals 42 a, 42 a′ and 42 b, 42 b′, or in conjunction with the spoke seals 42 a, 42 a′ and 42 b, 42 b′. The spoke opening cover 100 basically has a resilient tubular body 101 constructed from a flexible material such as rubber. The spoke opening cover 100 has a plurality of slits 102 spaced circumferential around the tubular body 101. The tubular body 101 of the spoke opening cover 100 is configured and dimensioned to snugly fit around the bicycle hub 22′ so that the spoke openings are aligned with the slits. The spoke opening cover 100 is installed on each end of the hub body 38′ prior to installation of spokes 24. Since this embodiment is used with the bicycle hubs 22 and 22′, the slits 102 extend diagonally relative a center axis of the tubular body. The slits 102 have enlarged openings 104 at each end. The enlarged openings 104 align with the retaining portions 62′ of the spoke openings 60 a′ or 60 b′, while the center sections of the slits 102 overlie the insertion portions 61′ of the spoke openings 60 a′ or 60 b′. Also, the center sections of the slits 102 hold the spokes 24 in the retaining portions 62′ to aid in the assembly of the wheel.

As seen in FIGS. 21 and 22, a spoke opening cover 100′ in accordance with an alternate embodiment of the present invention is illustrated for use with the bicycle either the rear hub 22 of FIGS. 4 and 5 or the front hub 22′ of FIGS. 15 and 16. Although for purposes of brevity, the spoke opening cover 100′ will only be illustrated with the front hub 22′.

The spoke opening cover 100′ is used to limit or prevent contaminants from entering the hub body 38 or 38′ via the spoke openings 60 a, 60 a′ or 60 b, 60 b′, respectively. The spoke opening cover 100′ can be used instead of the spoke seals 42 a, 42 a′ and 42 b, 42 b′, or in conjunction with the spoke seals 42 a, 42 a′ and 42 b, 42 b′. In this embodiment, the spoke opening cover 100′ is a thin flexible strip or body portion 101′ having a first end 102′ and a second end 104′ with a predetermined length therebetween. The first end 102′ is provided with a first protrusion 106′, while the second end 104′ is provided with a second protrusion 108′. The first and second protrusions 106′ and 108′ are configured and dimensioned to be frictionally retained with the insertion portions 61′ of the spoke openings 60 a′ or 60 b′. Accordingly, the first and second protrusions 106′ and 108′ have predetermined widths or diameters that are larger that a width of an enlarged head 24 c of a spoke 24. Preferably, the body portion 101′ has a predetermined width that is larger that the widths or diameters of the enlarged heads 24 c of the spokes 24. In other words, the body portion 101′ of the spoke opening cover 100′ has a predetermined width that is larger than a width of insertion portions 61′ of the spoke openings 60 a′ or 60 b′. The spoke opening cover 100′ is designed to be installed on each end of the hub body 38′ after the spokes 24 have been installed into the spoke openings 60 a′ and 60 b′.

As seen in FIGS. 23-25, a spoke opening cover 100″ in accordance with another alternate embodiment of the present invention is illustrated for use with the bicycle either the rear hub 22 of FIGS. 4 and 5 or the front hub 22′ of FIGS. 15 and 16. Although for purposes of brevity, the spoke opening cover 100″ will only be illustrated with the front hub 22′.

The spoke opening cover 100″ is used to limit or prevent contaminants from entering the hub body 38 or 38′ via the spoke openings 60 a, 60 a′ or 60 b, 60 b′, respectively. The spoke opening cover 100″ can be used instead of the spoke seals 42 a, 42 a′ and 42 b, 42 b′, or in conjunction with the spoke seals 42 a, 42 a′ and 42 b, 42 b′. In this embodiment, the spoke opening cover 100″ is a thin flexible strip or body portion 101″ having a first end 102″ and a second end 104″ with a predetermined length therebetween.

The first end 102″ is provided with a tubular connector 106″, while the second end 104″ is provided with a mating connector 108″. The tubular connector 106″ is a protrusion that is configured and dimensioned to be received in one of the insertion portions 61′ of the spoke openings 60 a′ or 60 b′. The mating connector 108′ is a split protrusion in the form of a resilient detent. The second end 104″ is configured and dimensioned to overlap the first end 102″ with mating connector 108″ being retained in the bore of tubular protrusion 106″ via a snap-fit. The length of body portion 101″ should be such that spoke opening cover 100″ snugly fits around the hub body 38′ when the detent 108″ is snap-fitted into the tubular protrusion 106″.

Preferably, the body portion 101″ has a predetermined width that is larger than the widths or diameters of the enlarged heads 24 c of the spokes 24. In other words, the body portion 101″ of the spoke opening cover 100″ has a predetermined width that is larger than a width of insertion portions 61′ of the spoke openings 60 a′ or 60 b′. The spoke opening cover 100″ is designed to be installed on each end of the hub body 38′ after the spokes 24 have been installed into the spoke openings 60 a′ and 60 b′.

Second Embodiment

Referring now to FIGS. 26-29, bicycle rear and front hubs 122 and 122′ are illustrated in accordance with a second embodiment of the present invention. The rear and front hubs 122 and 122′ of this second embodiment are substantially the same as the first embodiment, except that the spoke hole openings 60 a, 60 a′ and 60 b, 60 b′ of the first embodiment have been replaced with modified spoke openings 160 a, 160 a′ and 160 b, 160 b′ that each receive a single spoke as explained below. Since the rear and front hubs 122 and 122′ are substantially the same as the rear and front hubs 22 and 22′ of the first embodiment, this embodiment will not be discussed or illustrated in detail herein.

Referring to FIGS. 26 and 27, the rear hub 122 basically includes a hub axle 136, a hub body 138, a first bearing assembly 140 a, a second bearing assembly 140 b, a first spoke seal 142 a, a second spoke seal 142 b, a freewheel 144 and a quick release mechanism 146. The hub axle 136 has a center axis A extending between a first end 136 a and a second end 136 b.

The quick release mechanism 146 extends through a center bore 136 c of the hub axle 136 such that the quick release mechanism 146 is coupled to the hub axle 136 in a conventional manner. The first and second ends 136 a and 136 b of the hub axle 136 are threaded for receiving a pair of nuts 150 a and 150 b that applies an axial force on the hub body 138, the bearing assemblies 140 a and 140 b, the spoke seals 142 a and 142 b, and the freewheel 144. First and second bearing assemblies 140 a and 140 b rotatably mount the hub body 138 with the freewheel 144 on the hub axle 136. The freewheel 144 allows the hub axle 136 to rotate freely relative to the hub body 138 in one direction, but fixedly couples the hub axle 136 relative to the hub body 138 in the opposite rotational direction.

A set of first spoke openings 160 a are provided at the first end section 138 a of the hub body 138 for receiving the bent ends 24 b of the spokes 24. Similarly, the second end section 138 b of the hub body 138 is provided with a second set of spoke openings 160 b for receiving the bent ends 24 b of the spokes 24. In the illustrated embodiment, the first end section 138 a is provided with eighteen of the first spoke openings 160 a and the second end section 138 b is provided with eighteen of the second spoke openings 160 b. The spoke openings 160 a and 160 b are grouped into pairs that are equally spaced apart about the circumference of the hub body 138. Accordingly, the rear hub 122 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

Preferably, the first and second sets of spoke openings 160 a and 160 b are arranged identical. The first and second spoke openings 160 a and 160 b are designed to be used with conventional tangential spokes 24. Of course, it is possible that the first and second sets of spoke openings 160 a and 160 b can be different such that tangential spokes 24 are used in one end of the hub body 138 and a different types of spokes are used in the other end of the hub body 138. The first spoke openings 160 a are circumferentially arranged around the hub body 138 adjacent to the brake rotor attachment portion 138 d. Preferably, the first spoke openings 160 a are spaced axially inward of the brake rotor attachment portion 138 d so that brake disc rotor 132 can be easily attached with the bolts 132 a and nuts 132 b.

In this embodiment, the spoke openings 160 a and 160 b are arranged to form two circumferential rows of spoke openings 160 a at end section 138 a and two circumferential rows of spoke openings 160 b at end section 138 b. Each of the spoke openings 160 a and 160 b has an insertion portion 161 and a retaining portion 162. Adjacent pairs of the spoke openings 160 a and 160 b are oriented in opposite directions so that the spokes 24 extend in generally opposite directions from the hub body 138.

Each insertion portion 161 is formed by a curved or partial cylindrical surface 164 that has a width or diameter that is equal to or slightly larger than the widths or diameters of the enlarged heads 24 c of the spokes 24. Thus, the inner ends (bent ends 24 b with enlarged heads 24 c) of the spokes 24 can be easily inserted into the spoke openings 160 a and 160 b through the insertion portions 161.

The retaining portions 162 have smaller widths or diameters than the insertion portions 161. More specifically, the diameters or widths of the retaining portions 162 are smaller than the diameters or widths of the enlarged heads 24 c of the spokes 24 so as to retain the spokes 24 within the spoke openings 160 a and 160 b. The retaining portions 162 are each preferably defined by a partial cylindrical surface 166 that is connected to the curved surface 164 of the associated insertion portion 161.

Preferably, the insertion portion 161 and the retaining portions 162 of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 162 of the spoke openings 160 a and 160 b are tapered to avoid sharp edges engaging the spokes 24.

Similar to the first embodiment, discussed above, each of the insertion portions 161 has a center longitudinal axis that passes through the center axis A of the hub axle 136. The retaining portions 162, on the other hand, have center longitudinal axes that are parallel to the center longitudinal axis of the associated insertion portion 161 for each of the spoke openings 160 a and 160 b. Thus, the center longitudinal axes of the retaining portions 162 do not pass through the center axis of the hub axle 136, similar to the first embodiment. Rather, the center longitudinal axes of the retaining portions 162 are angled with respect to center axis A. Preferably, the center longitudinal axis of each retaining portion 162 is angled between about 5° and about 20° from a radial orientation in the hub body 138. In the illustrated embodiment, the retaining portions 162 are angled about 10° with respect to center axis A for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 162 are preferably angled about 11° with respect to center axis A. This angled configuration of the retaining portions 162 results in the straight sections 24 a of the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 138. Moreover, this angled configuration of the retaining portions 162 allows the straight sections 24 a of the spokes 24 to be easily aligned with the spoke holes of the rim without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees.

Referring to FIGS. 28 and 29, the front hub 122′ basically includes a hub axle 136′, a hub body 138′, a first bearing assembly 140 a′, a second bearing assembly 140 b′, a first spoke seal 142 a′, a second spoke seal 142 b′, and a quick release mechanism 146′. The hub axle 136′ has a center axis A′ extending between a first end 136 a′ and a second end 136 b′.

The quick release mechanism 146′ extends through a center bore 136 c′ of the hub axle 136′ such that the quick release mechanism 146′ is coupled to the hub axle 136′ in a conventional manner. The first and second ends 136 a′ and 136 b′ of the hub axle 136′ are threaded for receiving a pair of nuts 150 a′ and 150 b′ that applies an axial force on the hub body 138′, the bearing assemblies 140 a′ and 140 b′ and the spoke seals 142 a′ and 142 b′. First and second bearing assemblies 140 a′ and 140 b′ rotatably mount the hub body 138′ on the hub axle 136′.

A set of first spoke openings 160 a′ are provided at the first end section 138 a′ of the hub body 138′ for receiving the bent ends 24 b of the spokes 24. Similarly, the second end section 138 b′ of the hub body 138′ is provided with a second set of spoke openings 160 b′ for receiving the bent ends 24 b of the spokes 24. In the illustrated embodiment, the first end section 138 a′ is provided with eighteen of the first spoke openings 160 a′ and the second end section 138 b′ is provided with eighteen of the second spoke openings 160 b′. The spoke openings 160 a′ and 160 b′ are grouped into pairs that are equally spaced apart about the circumference of the hub body 138′. Accordingly, the front hub 122′ is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

The first spoke openings 160 a′ are circumferentially arranged around the hub body 138′ adjacent to the brake rotor attachment portion 138 d′. Preferably, the first spoke openings 160 a′ are spaced axially inward of the brake rotor attachment portion 138 d′ so that brake disc rotor 132′ can be easily attached with the bolts 132 a′ and nuts 132 b′.

In this embodiment, the spoke openings 160 a′ and 160 b′ are arranged to form two circumferential rows of spoke openings 160 a′ at end section 138 a′ and two circumferential rows of spoke openings 160 b′ at end section 138 b′. Each of the spoke openings 160 a′ and 160 b′ has an insertion portion 161′ and a retaining portion 162′. Adjacent pairs of the spoke openings 160 a′ and 160 b′ are oriented in opposite directions so that the spokes 24 extend in generally opposite directions from the hub body 138′.

Each insertion portion 161′ is formed by a curved or partial cylindrical surface 164′ that has a width or diameter that is equal to or slightly larger than the widths or diameters of the enlarged heads 24 c of the spokes 24. Thus, the inner ends (bent ends 24 b with enlarged heads 24 c) of the spokes 24 can be easily inserted into the spoke openings 160 a′ and 160 b′ through the insertion portions 161′.

The retaining portions 162′ have smaller widths or diameters than the insertion portions 161′. More specifically, the diameters or widths of the retaining portions 162′ are smaller than the diameters or widths of the enlarged heads 24 c of the spokes 24 so as to retain the spokes 24 within the spoke openings 160 a′ and 160 b′. The retaining portions 162′ are each preferably defined by a partial cylindrical surface 166′ that is connected to the curved surface 164′ of the associated insertion portion 161′.

Preferably, the insertion portion 161′ and the retaining portions 162′ of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 162′ of the spoke openings 160 a′ and 160 b′ are tapered to avoid sharp edges engaging the spokes 24.

Similar to the first embodiment, discussed above, each of the insertion portions 161′ has a center longitudinal axis that passes through the center axis A′ of the hub axle 136′. The retaining portions 162′, on the other hand, have center longitudinal axes that are parallel to the center longitudinal axis of the associated insertion portion 161′ for each of the spoke openings 160 a′ and 160 b′. Thus, the center longitudinal axes of the retaining portions 162′ do not pass through the center axis of the hub axle 136′, similar to the first embodiment. Rather, the center longitudinal axes of the retaining portions 162′ are angled with respect to center axis A′. Preferably, the center longitudinal axis of each retaining portion 162′ is angled between about 5° and about 20° from a radial orientation in the hub body 138′. In the illustrated embodiment, the retaining portions 162′ are angled about 10° with respect to center axis A′ for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 162′ are preferably angled about 11° with respect to center axis A′. This angled configuration of the retaining portions 162′ results in the straight sections 24 a of the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 138′. Moreover, this angled configuration of the retaining portions 162′ allows the straight sections 24 a of the spokes 24 to be easily aligned with the spoke holes of the rim without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees.

While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing description of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 

What is claimed is:
 1. A bicycle hub for use with bicycle spokes, said bicycle hub comprising: a hub axle having a center axis extending between a first end and a second end; a hub body having a center tubular portion defining an interior passageway with said hub axle being rotatably supported therein, a brake rotor attachment portion located at a first end section of said center tubular portion, and a plurality of first spoke openings adjacent said brake rotor attachment portion; and a freewheel coupled to said second end of said axle adjacent a second end section of said hub body, said first spoke openings extending through said first end section of said center tubular portion of said hub body, said brake rotor attachment portion being integrally formed with said center tubular portion as a one-piece, unitary member, said brake rotor attachment portion having a plurality of through bores.
 2. A bicycle hub according to claim 1, wherein said through bores are unthreaded bores.
 3. A bicycle hub according to claim 2, further comprising a bolt located in each of said through bores and a nut threadedly coupled to each of said bolts.
 4. A bicycle hub according to claim 1, further comprising a bolt located in each of said through bores and a nut threadedly coupled to each of said bolts.
 5. A bicycle hub according to claim 1, wherein said through bores are threaded bores.
 6. A bicycle hub according to claim 5, further comprising a bolt threadedly coupled in each of said through bores.
 7. A bicycle hub according to claim 6, wherein a nut threadedly coupled to each of said bolts.
 8. A bicycle hub according to claim 1, wherein said center tubular portion with said brake rotor attachment portion being constructed of aluminum.
 9. A bicycle hub according to claim 1, wherein said brake rotor attachment portion has six of said through bores.
 10. A bicycle hub according to claim 1, further comprising a brake rotor coupled to said through bores of said brake rotor attachment portion by bolts.
 11. A bicycle hub according to claim 1, wherein said hub body has at least eight of said first spoke openings.
 12. A bicycle hub according to claim 1, wherein said hub body has at least sixteen of said first spoke openings.
 13. A bicycle hub according to claim 1, wherein each of said first spoke openings has a first insertion portion with a large width that permits an enlarged head portion of a spoke to pass therethrough and a first retaining portion with a width that is smaller than said width of said first insertion portion to retain the enlarged head portion of the spoke therein.
 14. A bicycle hub according to claim 13, wherein each of said first spoke openings includes a second additional retaining portion to retain the enlarged head portions of two spokes within each of said first spoke openings.
 15. A bicycle hub according to claim 13, wherein said through bores are unthreaded bores.
 16. A bicycle hub according to claim 15, further comprising a bolt located in each of said through bores and a nut threadedly coupled to each of said bolts.
 17. A bicycle hub according to claim 13, wherein said through bores are threaded bores.
 18. A bicycle hub according to claim 17, further comprising a bolt threadedly coupled in each of said through bores.
 19. A bicycle hub according to claim 18, further comprising a nut threadedly coupled to each of said bolts.
 20. A bicycle hub according to claim 1, wherein said hub body further includes a set of second spoke openings circumferentially arranged around said hub body at a second end section that is axially spaced from said first spoke openings. 